Conical substrate

Patent metadata

Field	Value
Publication number	US-9222393-B2
Application number	US-201213723309-A
Country	US
Kind code	B2
Filing date	Dec 21, 2012
Priority date	Dec 21, 2012
Publication date	Dec 29, 2015
Grant date	Dec 29, 2015

Abstract

A catalytic converter for use in motor vehicle exhaust systems includes a housing and a catalytic substrate disposed in the housing. The housing includes a central shell fixed to an inlet end cone and an outlet end cone. The catalytic substrate includes a primary body section disposed in an internal chamber of the central shell and a secondary body section disposed in an inlet chamber of the inlet end cone. The secondary body section includes a shaped face surface that is exposed to hot exhaust gases supplied to the inlet chamber to assist in improved light-off and improved purification efficiency.

First claim

What is claimed is:

1. A catalytic converter for purifying exhaust gas from an engine, comprising:
a housing defining an inlet chamber for receiving the exhaust gas, a central internal chamber communicating with the inlet chamber, and an outlet chamber communicating with the central internal chamber for exhausting the purified gas;
a catalytic substrate having a first body section disposed within said central chamber and a second body section disposed within said inlet chamber, said second body section having a contoured inlet face surface; and
a seal ring disposed between said second body section and said housing, said seal ring prohibiting the exhaust gas from flowing between said second body section and said housing; wherein
said first body section defines a first cylindrical surface and said second body section defines a second cylindrical surface, said second cylindrical surface extending axially from a proximal end surface of said first body section and being parallel to said first cylindrical surface and having a diameter less than said first cylindrical surface;
said seal ring directly engaging said first cylindrical surface and directly engaging said second cylindrical surface;
the housing includes an inlet end cone defining said inlet chamber; and
said inlet cone end defines a radially inward extending flange in direct contact with said seal ring, the radially inward extending flange extending radially inward from a terminal end of the inlet end cone.

2. The catalytic converter of claim 1 wherein said housing includes a shell defining said central chamber;
said inlet end cone is secured to one end of said shell to define said inlet chamber,
said housing further includes an outlet end cone secured to an opposite end of said shell to define said outlet chamber,
said inlet end cone has an inlet port for receiving the exhaust gas from the engine,
said outlet end cone has an outlet port for exhausting the purified gas to a tail pipe, and
said second body section of said catalytic substrate extends into said inlet chamber toward said inlet port.

3. The catalytic converter of claim 2 wherein said contoured inlet face surface on said second body section of said catalytic substrate includes a conical face surface.

4. The catalytic converter of claim 3 wherein said conical face surface is truncated by a transversely extending face surface that is generally aligned with said inlet port.

5. The catalytic converter of claim 2 wherein said contoured inlet face surface on said second body section of said catalytic substrate is arcuate and defines a partial spherical second body section.

6. The catalytic converter of claim 2 wherein said catalytic substrate further includes a third body section disposed within said outlet chamber and which has a contoured outlet face surface.

7. The catalytic converter of claim 6 wherein said inlet face surface and said outlet face surface are conical.

8. The catalytic converter of claim 7 wherein said conical inlet face and said conical outlet face surface are symmetrical relative to an axis passing through said inlet port and said outlet port.

9. The catalytic converter of claim 6 wherein said inlet face surface and said outlet face surface are arcuate and define partially spherical second and third body sections.

10. The catalytic converter of claim 6 wherein said catalytic substrate is divided into a first brick and a second brick aligned generally adjacent to each other, wherein said first brick defines said second body section which extends into said inlet chamber, and wherein said second brick defines said third body section which extends into said outlet chamber.

11. A catalytic converter for purifying exhaust gases from an engine, comprising:
a housing having a shell, an inlet end cone extending from a first end of said shell, and an outlet end cone extending from a second end of said shell, said inlet end cone defining an inlet port for receiving the exhaust gas and an inlet chamber communicating with said inlet port, said shell defining a central chamber communicating with said inlet chamber, said outlet end cone defining an outlet chamber communicating with said central chamber and an outlet port for exhausting the purified gases;
a catalytic substrate having a first body section disposed within said central chamber and a second body section disposed within said inlet chamber, wherein said second body section includes a contoured inlet face surface extending toward said inlet port; and
a seal ring disposed between said second body section and said housing, said seal ring prohibiting the exhaust gas from flowing between said second body section and said housing; wherein
said first body section defines a first cylindrical surface and said second body section defines a second cylindrical surface, said second cylindrical surface extending axially from a proximal end surface of said first body section and being parallel to said first cylindrical surface and having a diameter less than said first cylindrical surface;
said seal ring directly engaging said first cylindrical surface and directly engaging said second cylindrical surface; and
said inlet cone end defines a radially inward extending flange in direct contact with said seal ring, the radially inward extending flange extending radially inward from a terminal end of the inlet end cone.

12. The catalytic converter of claim 11 wherein said contoured inlet face surface on said second body section of said catalytic substrate includes a conical face surface.

13. The catalytic converter of claim 12 wherein said conical inlet face surface is truncated by a transversely extending face surface that is generally aligned with said inlet port.

14. The catalytic converter of claim 11 wherein said contoured inlet face surface on said second body section of said catalytic substrate is arcuate and defines a partial spherical second body section.

15. The catalytic converter of claim 11 wherein said catalytic substrate further includes a third body section disposed within said outlet chamber and which has contoured outlet face surface.

16. The catalytic converter of claim 15 wherein said inlet face surface and said outlet face surface are conical.

17. The catalytic converter of claim 16 wherein said conical inlet face surface and said conical outlet face surface are symmetrical relative to an axis passing through said inlet port and said outlet port.

18. The catalytic converter of claim 15 wherein said inlet face surface and said outlet face surface are arcuate and define partially spherical second and third body sections.

19. The catalytic converter of claim 11 wherein said catalytic substrate is divided into a first brick and a second brick aligned generally adjacent to each other, wherein said first brick defines said second body section which extends into said inlet chamber, and wherein said second brick defines said third body section which extends into said outlet chamber.

Assignees

• Denso Int America Inc

Inventors

• Duda Andre

Classifications

• F01N3/022

  characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous · CPC title

• B01D46/2422

  Mounting of the body within a housing · CPC title

• F01N3/28

  Construction of catalytic reactors · CPC title

• F01N3/2892 Primary

  Exhaust flow directors or the like, e.g. upstream of catalytic device · CPC title

• B01D46/2455

  of the whole honeycomb or segments · CPC title